Appliance control system with cycle selection detection

ABSTRACT

An appliance controller includes a control knob assembly and detection mechanism having various mechanical and electrical components that are configured to detect the position of the knob assembly and produce a position signal indicative of the knob assembly position. The position signal is provided to the appliance controller that produces a control signal in response thereto. The control signal is used to initiate various appliance functions based on the specific position of the knob assembly. In one form, the detection mechanism includes a variable resistor assembly that is comprised of a wiper and resistor pad arrangement. In another form, the detection mechanism includes a shaft encoder mechanism that is comprised of a light transmitter and receiver, and an associated apertured disc secured to the knob assembly.

This application claims the benefit of and/or priority to U.S.provisional application Ser. No. 60/310,695 filed Aug. 6, 2001, entitled“Appliance Control System.”

CROSS-REFERENCE TO RELATED APPLICATIONS

Cross-reference is made to U.S. patent application entitled “ApplianceControl System With Power Controller” by Peterson, Ser. No. 10/xxx,xxxand attorney docket number 1007-0551; U.S. patent application entitled“Appliance Control System With Hyperspin Mode” by Peterson, Ser. No.10xxx,xxx and attorney docket number 1007-0552; U.S. patent applicationentitled “Appliance Control System With Auxiliary Inputs” by Petersonand Stultz, Ser. No. 10xxx,xxx and attorney docket number 1007-0553;U.S. patent application entitled “Appliance Control System With LEDOperation Indicators” by Peterson and Stultz, Ser. No. 10xxx,xxx andattorney docket number 1007-0555; U.S. patent application entitled“Appliance Control System With Network Accessible Programmable Memory”by Peterson, Ser. No. 10xxx,xxx and attorney docket number 1007-0556;U.S. patent application entitled “Appliance Control System With KnobControl Assembly” by Peterson and Stultz, Ser. No. 10xxx,xxx andattorney docket number 1007-0557; and U.S. patent application entitled“Appliance Control System With Solid State Appliance Controller” byPeterson, Ser. No. 10xxx,xxx and attorney docket number 1007-0558; allof which are commonly assigned and filed on even date herewith.

FIELD OF THE INVENTION

The present invention relates generally to appliances, and moreparticularly, to a control system for an appliance.

BACKGROUND

Appliances such as washing machines, dryers, ovens, and the like,typically include a plurality of knobs, dials, input pads, switchesand/or the like. Such knobs, dials, input pads, switches and/or the likefunction as user inputs, user input controls, controls, controllersand/or the like. In most instances, the controls provide for discreteselection of various modes, cycles, states, choices, parameters, and/orthe like of the appliance.

In the case of washing machines, a main knob or dial is utilized forselecting the laundry cycle and a length of time of the selected cycle.The rotational position of the main knob is correlated to particularcycle/time selections and thus determines a selection. The main knob ordial typically additionally incorporates a mechanical timer mechanism.The other knobs also utilize rotational position to select and/orindicate the selection.

Such knobs and/or dials heretofore have been constructed utilizinganalog components. Analog components provide the desired discreteselection capability and provide tactile feel associated with the chosenselection. The knobs and/or dials, however, can suffer failure forvarious reasons such as mechanical breakdown or fatigue. Shaft orrotational position may be difficult if not impossible for the applianceto determine with worn components. Additionally, mechanical knobs and/ordials are relatively heavy. It would thus be desirable to have anappliance controller that is not mechanical but still provides the samefunctionality as heretofore mechanical input devices. More particularly,it would be desirable to have an electronic appliance controller such asa knob or dial that at least partially electronically provides detectionof selected position.

SUMMARY

An appliance controller comprises a control knob assembly that at leastpartially electronically detects, determines and/or monitors rotationalposition to determine user selection.

An appliance controller comprises a control knob assembly and detectionmechanism having various mechanical and electrical components that areconfigured to detect the position of the knob assembly and produce aposition signal indicative of the knob assembly position. The positionsignal is provided to the appliance controller that produces a controlsignal in response thereto. The control signal is used to initiatevarious appliance functions based on the specific position of the knobassembly.

In one form, the subject invention provides an appliance control systemthat is operable in a user cycle selection mode and a cycle operationmode. The appliance control system includes a housing, a display devicesupported by the housing, a user cycle selector at least partiallypositioned within the housing, a printed circuit board supported by thehousing; a circuit configured to (i) operate the display device duringthe user cycle selection mode to indicate position status of the usercycle selector; and (ii) operate the display device during the cycleoperation mode to indicate cycle progression status of the appliancecontrol system, the circuit includes a circuit pattern assemblysupported by the printed circuit board, and a wiper assembly positionedwithin the housing. The user cycle selector is movable from a firstselector position to a second selector position in relation to a circuitpattern assembly, wherein the circuit is configured to operate thedisplay device to indicate a first position status which corresponds tothe first selector position when the wiper assembly is positioned incontact with the circuit pattern assembly at a first orientation, andwherein the circuit is configured to operate the display device toindicate a second position status which corresponds to the secondselector position when the wiper assembly is positioned in contact withthe circuit pattern assembly at a second orientation.

In another form, the subject invention provides an appliance controlsystem that is operable in a user cycle selection mode and a cycleoperation mode. The appliance control system includes a display device,a user cycle selector that is movable from a first selector position toa second selector position, a wiper assembly, and a circuit configuredto (i) operate the display device during the user cycle selection modeto indicate position status of the user cycle selector; and (ii) operatethe display device during the cycle operation mode to indicate cycleprogression status of the appliance control system, the circuitincluding a circuit pattern assembly. The circuit is configured tooperate the display device to indicate a first position status whichcorresponds to the first selector position when the wiper assembly ispositioned in contact with the circuit pattern assembly at a firstorientation. The circuit is further configured to operate the displaydevice to indicate a second position status which corresponds to thesecond selector position when the wiper assembly is positioned incontact with the circuit pattern assembly at a second orientation.

In a further form, the subject invention provides an appliance controlsystem that is operable in a user cycle selection mode and a cycleoperation mode. The appliance control system includes a user cycleselector, a wiper assembly, wherein movement of the user cycle selectorcauses movement of the wiper assembly, and a circuit pattern assemblypositioned in contact with the wiper assembly. The switching of theappliance control system from the user cycle selection mode to the cycleoperation mode when the wiper assembly is positioned in contact with thecircuit pattern assembly at a first orientation causes a first selectedcycle of the cycle operation mode to be performed by the appliancecontrol system. The switching of the appliance control system from theuser cycle selection mode to the cycle operation mode when the wiperassembly is positioned in contact with the circuit pattern assembly at asecond orientation causes a second selected cycle of the cycle operationmode to be performed by the appliance control system.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention,and the manner of attaining them, will become more apparent and theinvention will be better understood by reference to the followingdescriptions of embodiments of the invention taken in conjunction withthe accompanying drawings, wherein:

FIG. 1 is a perspective view of a washing machine embodying the variousaspects of the various inventions shown and described herein;

FIG. 2 is a block diagram of the washing machine of FIG. 1;

FIG. 3 is a block diagram of an exemplary power supply for the washingmachine of FIG. 1;

FIG. 4 is another block diagram of the exemplary power supply;

FIG. 5 is an electrical schematic of the exemplary power supply;

FIG. 6 is a flowchart of an exemplary manner of operation of theexemplary power supply;

FIG. 7 is a block representation of the appliance control system showinga plurality of auxiliary inputs;

FIG. 8 is a further representation of the appliance control system ofFIG. 7;

FIG. 9 is a simplified electrical schematic of the representation ofFIGS. 7 and 8;

FIG. 10 is a partial electrical schematic of the appliance controlsystem in accordance with the principles presented herein;

FIG. 11 is a partial electrical schematic of the appliance controlsystem;

FIG. 12 is a partial electrical schematic of the appliance controlsystem;

FIG. 13 is a flowchart of an exemplary manner of operation of theauxiliary inputs of the present invention;

FIG. 14 is a block diagram representation of a hyperspin feature inaccordance with an aspect of the present invention;

FIG. 15 is another block diagram representation of the hyperspinfeature;

FIG. 16 is another block representation of the hyperspin feature;

FIG. 17 is a partial electrical schematic of the hyperspin portion ofthe appliance control system;

FIG. 18 is a partial electrical schematic of the motor portion;

FIG. 19 is a flowchart of an exemplary manner of operation of thehyperspin feature in accordance with the principles of the presentinvention;

FIG. 20 is a block representation of a communication feature inaccordance with the principles of the present invention;

FIG. 21 is a block representation of water control features of thepresent invention;

FIG. 22 is a partial electrical schematic of the appliance controlsystem showing the water control features and the user cycle selectioninput;

FIG. 23 is one part of a partial electrical schematic of the appliancecontrol system showing the LEDs;

FIG. 24 is another part of the partial electrical schematic of theappliance control system of FIG. 23;

FIG. 25 is a front elevational view of the main controller module thatis used in the washing machine of FIG. 1;

FIG. 26 is a bottom elevational view of the main controller module ofFIG. 25;

FIG. 27 is a rear elevational view of the main controller module of FIG.25;

FIG. 28 is an exploded perspective view of the main controller module ofFIG. 25;

FIG. 29 is an assembled perspective view of part of the user selectorassembly of the main controller module of FIG. 25;

FIG. 30 is an exploded perspective view of various parts of the userselector assembly of the main controller module of FIG. 25;

FIG. 31 is a front elevational view of the housing of the maincontroller module of FIG. 25;

FIG. 32 is a cross sectional view taken along the line 32—32 of FIG. 31of the housing of the main controller module of FIG. 25;

FIG. 33 is a rear elevational view of the housing of the main controllermodule of FIG. 25;

FIG. 34 is a front perspective view of the housing of the maincontroller module of FIG. 25;

FIG. 35 is a rear perspective view of the housing of the main controllermodule of FIG. 25;

FIG. 36 is a rear elevational view of the escutcheon of the maincontroller module of FIG. 25;

FIG. 37 is a side elevational view of the escutcheon of the maincontroller module of FIG. 25;

FIG. 38 is a cross sectional view of the escutcheon of the maincontroller module of FIG. 25 taken along the line 38—38 of FIG. 36;

FIG. 39 is a perspective view of the second spring of the maincontroller module of FIG. 25;

FIG. 40 is a side elevational view of the second spring of the maincontroller module of FIG. 25;

FIG. 41 is a first side elevational view of the control shaft of themain controller module of FIG. 25;

FIG. 42 is a second side elevational view of the control shaft of themain controller module of FIG. 25;

FIG. 43 is an enlarged view of the part of FIG. 42 that is encircled andlabeled FIG. 43;

FIG. 44 is a cross sectional view of the reduced diameter portion of thecontrol shaft of the main controller module of FIG. 25 taken along theline 44—44 of FIG. 42;

FIG. 45 is a first side elevational view of the first spring of the maincontroller module of FIG. 25;

FIG. 46 is a second side elevational view of the first spring of themain controller module of FIG. 25;

FIG. 47 is a front elevational view of the wiper assembly of the maincontroller module of FIG. 25;

FIG. 48 is a rear elevational view of the wiper assembly of the maincontroller module of FIG. 25;

FIG. 49 is a side elevational view of the wiper assembly of the maincontroller module of FIG. 25;

FIG. 50 is an elevational view of the circuit pattern assembly of themain controller module of FIG. 25;

FIG. 51 is an elevational view of the front side of the first printedcircuit board and the front side of the second printed circuit board ofthe main controller module of FIG. 25 (note that after assembly of themain controller module, the second printed circuit board is positionedunder the first printed circuit board, however for clarity of viewing,FIG. 51 shows the second printed circuit board pivoted to a locationadjacent to the first printed circuit board);

FIG. 52 is an elevational view of the back side of the first printedcircuit board and the back side of the second printed circuit board ofthe main controller module of FIG. 25 (note that for clarity of viewing,FIG. 52 shows the second printed circuit board pivoted in a mannersimilar to that shown in FIG. 51);

FIG. 53 is an elevational view of an informational overlay of the maincontroller module of FIG. 25;

FIG. 54 is an enlarged fragmentary view of the informational overlay ofFIG. 53;

FIG. 55 is a schematic diagram of a first alternative shaft positiondetection mechanism which can be used in the main controller moduleand/or any of the auxiliary input units of the appliance control systemof the present invention;

FIG. 56 is a schematic diagram of a second alternative shaft positiondetection mechanism which can be used in the main controller moduleand/or any of the auxiliary input units of the appliance control systemof the present invention; and

FIG. 57 is a perspective view of a dryer embodying the various aspectsof the various inventions shown and described herein.

Corresponding reference characters indicate corresponding partsthroughout the several views.

DETAILED DESCRIPTION

Referring to FIG. 1, there is depicted a washing machine, generallydesignated 5, representing one form of a laundry appliance. The washingmachine 5 has a frame 36 that houses a receptacle or tub 32 that isconfigured to receive laundry therein for washing. The tub 32 isaccessed via a pivoting door or lid 38 in the frame 36. The tub 32 ismounted in the frame 36 so as to revolve or spin, typically (and asshown) around a vertical axis 46. The tub 32 is in communication with amotor 26 that is likewise mounted in the frame 36, and which isoperative to spin the tub 32 in a controlled manner as described below.

The washing machine 5 also has a control panel frame 40 that houses anappliance control system 10. External to the control panel frame 40 andpart of the appliance control system 10 is a main controller module 300and a plurality of auxiliary inputs 44 (typically in the form of knob,switches, or the like). The controller module 300 provides operatingmode/cycle indication and/or control of the operating mode/cycle for/ofthe washing machine 5. Power for the washing machine 5 is provided via apower cord 48 that is configured to be plugged into an appropriatesource of electricity, typically a 120 volt AC source or a 240 volt ACsource (not shown). The general operation of the washing machine 5, withrespect to the loading, washing, and unloading of laundry, is typical ofwashing machines.

The appliance control system 10 also includes a communication port 50that allows the washing machine 5 to be coupled to or in communicationwith an external device, network, or the like. The communication port 50may take the form of an RS-232 port, a telephone-type port, or the like.Particularly, the communication port 50 allows the washing machine 5 tobe in communication with a test/diagnostic device, a public and/orprivate network such as the Internet, another laundry appliance, orother device.

Referring to FIG. 2 there is depicted a block diagram of the washingmachine 5. The washing machine 5 includes the appliance control system(ACS) 10, the motor 26, the door or lid switch 28, a water temperaturesensor 30, the receptacle or tub 32, and water supply solenoid valves34. The ACS 10 is operative to control variousaspects/features/functions of the washing machine 5 as explained ingreater detail below, and to indicate the various cycles of the washingmachine 5. The ACS 10 includes various sections, modules, portions, orthe like the nature and manner of operation of which will be describedbelow. As indicated above, the motor 26 is operative to rotate the tub32 during the various cycles or modes of the washing machine 5. The tub32 is adapted to hold an amount of laundry and water for washing. Thelid switch 28 is operative to interrupt or stop the motor 26 or causethe washing machine 5 to not continue its operating cycle when the lid38 is opened during operation. The lis switch 28 also prevents the startof a cycle if the lid 38 is initially open. Therefore, the lid 38 mustbe closed in order for the washing machine 5 to begin an operatingcycle. The water temperature sensor 30 is operative to provide watertemperature data to the ACS 10 regarding temperature of the water goinginto the tub 32 or already in the tub 32 in order to provide theproper/appropriate washing water temperature. The water supplysolenoids/valves 34 are operative to control the flow of hot and/or coldwater into the tub 32.

The ACS 10 includes an auxiliary user interface selector 12 for thewashing machine. The auxiliary user interface selector 12 isadapted/configured via appropriate circuitry, logic, and/or componentsto allow a user to select various washing machine parameters.Particularly, the auxiliary user interface selector 12 is operative toallow the user to select various washing machine parameters or operatingcycle options (options) of various washing machine cycles or modes. Apower control system 14 is provided in the ACS 10 that is operative,configured, and/or adapted via appropriate circuitry, logic, and/orcomponents to provide power to the various components of the washingmachine 5. More particularly, the power control system 14 is operativeto provide a standby or low power and/or an operating power to thevarious components of the washing machine 5.

The ACS 10 also has a hyperspin control system 16 that is operative,configured, and/or adapted via appropriate circuitry, logic and/orcomponents to provide a hyperspin feature or function. The hyperspinfeature/function permits the tub 32 to spin or rotate at a speed that isgreater than a normal tub rotation speed, typically during a dryingcycle of the washing machine 5. The ACS 10 further has a main controllermodule 300 that is operative, configured, and/or adapted to allow theuser to select various operating modes, cycles or the like of thewashing machine 5. The main controller module 300 includes a selectordisplay 20. The selector display 20 is operative, configured, and/oradapted via appropriate circuitry, logic, and/or components to provideinformation regarding the user selection. The selector display 20 isalso operative to indicate or show the progression of the user selectionas the washing machine performs the user selection. The selector display20 includes a plurality of light emitting devices 307 as will bediscussed below

The ACS 10 further includes a communication interface 22. Thecommunication interface 22 is operative, configured, and/or adapted viaappropriate circuitry, logic, and/or components to allow the washingmachine 5 to interface with external components, circuitry, logic,networks, or the like. As well, the communication interface 22 allowsremote access to various features, functions, or the like of the washingmachine 5. Lastly, the ACS 10 includes sensor ports 24 that are adaptedto allow connection with various sensors and/or data inputs of thewashing machine 5.

Power Supply

Referring to FIG. 3 there is depicted a block diagram representation ofthe power control system 14 and other components and/or circuitry/logicof the washing machine 5. The washing machine 5 receives lineelectricity from a source of electricity that is typically a 120 volt ACor 240 volt AC electricity source (not shown) designated lineelectricity in. The AC electricity supplied to the washing machine 5from line electricity in will hereinafter be termed line electricity,regardless of its source and voltage. The line electricity is receivedby the washing machine 5 via the power cord 48 (see FIG. 1).

The line electricity is supplied via the power control system 14 to lineelectricity conditioning circuitry/logic 56 that is operative viaappropriate circuitry, logic, and/or components to provide the lineelectricity to line electricity components 58 of the washing machine 5.The line electricity components 58 include the motor 26 (direct use),the lid switch 28 (as pass-through) and any other washing machinecomponent that directly or indirectly utilizes the line electricity tooperate.

The power control system 14 is operative via appropriate circuitry,logic, and/or components to power or run operating power components 52and standby low power components 54 of the washing machine 5. Theoperating power components 52 include relays, transistors, triacs,silicon controlled rectifiers (SCRs), and the like. The standby lowpower components 54 include integrated circuits (ICs), auxiliary inputunits, clocks, and the like.

The power control system 14 includes operating power circuitry/logic 66that is operative to produce, generate, or derive operating power(electricity) from the line electricity for powering the operating powercomponents 52. As well, the power control system 14 includes standby lowpower circuitry/logic 64 that is operative to produce, generate, orderive standby and/or low power (electricity) from the line electricityfor powering the standby and/or low power components 54.

The operating power circuitry/logic 66 provides operating power to theoperating power components 52 when the washing machine 5 is in use. Thestandby low power circuitry/logic 64 provides standby power to thestandby power components 54 when the washing machine 5 is not in use butstill plugged into the line electricity as well as to low powercomponents 54 when the washing machine is in use. It should be notedthat the power control system 14 does not utilize a transformer togenerate and/or derive the operating power or the standby low power forthe washing machine 5. This is accomplished by utilizing electroniccomponent signal conditioning.

The standby low power provides electricity in a small or low amount inthe neighborhood of less than one watt, but which may be generated inany amount necessary for a standby state and a low power state of thewashing machine 5. In one embodiment, the generated standby low powerelectricity is approximately five (5) volts at a particular current thatyields standby power in the milliwatts. In an embodiment of a washingmachine ACS, whose circuitry/logic is described in detail below, thestandby low power produced by the standby power circuitry/logic 64 isaround 500 milliwatts. It should be understood that the standby lowpower produced by the standby low power circuitry/logic 64 is determinedby the standby operating conditions, parameters, or the like of theparticular standby low power components 54 of the washing machine 5.

The operating power provides electricity in an amount necessary tooperate, actuate, or use the various operating power components 52.Thus, the operating power generated by the operating powercircuitry/logic 66 is in accordance with design characteristics of thewashing machine 5. However, in one embodiment, the operating powercircuitry/logic 66 is operative to produce twenty-four (24) volts ofoperating electricity.

The power control system 14 also includes line cross circuitry/logic 62that is operative, configured, and/or adapted to generate, produce, orderive a line cross signal from the line electricity. The line crosssignal is represented by the arrow 72 and is provided to a processor 60of the washing machine 5. The processor 60 may be a processing unit,microprocessor, processing means, or the like. The processor 60 utilizesthe line cross signal for timing purposes.

The power control system 14 is operative in one of two modes or statesof operation. One state or mode of operation may be termed an idle orstandby mode, while the other state or mode of operation may be termed arun or operating mode. In the idle mode of operation, the standby powercircuitry/logic 64 provides standby power to the standby powercomponents 54, while the operating power circuitry/logic 66 is preventedfrom supplying operating power to the operating power components. In therun mode of operation, the operating power circuitry/logic 66 providesoperating power to the operating power components. At the same time(while in the run mode of operation) the standby low powercircuitry/logic 64 provides standby power to the standby low powercomponents. This is because the standby low power components 54 are anecessary part of the operation of the washing machine 5. For thisreason, the standby power may also be termed low power while the standbypower components may be termed low power components. The standby powercircuitry/logic 64 may thus be considered as supplying standby power tostandby components when the washing machine 5 is plugged in but notoperating, and as supplying low power to low power components when thewashing machine is operating. The standby components may not necessarilybe the same as the low power components.

When the washing machine 5 is receiving the line electricity, and not inuse (the idle or standby mode), the washing machine 5 is operative togenerate standby power via the standby power circuitry/logic 64 for thestandby power components 54. When a user turns actuates the washingmachine 5, without regard to the particular operating mode (the runmode), the washing machine 5 needs operating power as generated by theoperating power circuitry/logic 66. The particular components of theoperating power components 52 that require operating power is dependentupon the operating mode of the washing machine 5.

The power control system 14 regulates the application of the operatingpower to the operating power components 52 via switch/switchingcircuitry/logic 68. In accordance with an aspect of the presentinvention, the switch/switching circuitry/logic 68 (hereinafterswitching circuitry 68 for short) is operative to switch in or apply theoperating power from the operating power circuitry/logic 66 to theoperating power components 52 when appropriate or necessary for theoperation of the washing machine 5, or control of the application of theoperating power from the operating power circuitry/logic 66 to and forthe appropriate operating power components 52. This may includeintermittently applying the operating power to the operating powercomponents 52.

The switching circuitry 68 is regulated or controlled by a controlsignal that is provided to the switching circuitry 68 by a processor 60via a control line 70. The control signal actuates the switchingcircuitry 68, causing the operating power circuitry/logic 66 generatingthe operating power for the operating power components 52 to be suppliedor applied to the operating power components 52. In accordance with oneembodiment, the operating power for the electronic components istwenty-four (24) volts, but may be any operating voltage that isappropriate. The control signal is provided to the switching circuitry68 when the washing machine 5 is actuated into a run or operating mode.This is typically accomplished through user actuation of a controlknob/on/off switch of the washing machine 5. Particularly, the washingmachine 5 is actuated into a washing cycle or operation via a useractuating a control input of the washing machine 5. In one form, thecontrol signal is pulsed.

Referring now to FIG. 4, there is depicted a more detailed block diagramof the washing machine 5 and, more particularly, of the power controlsystem 14. The washing machine 5 includes various sensors and datainputs generally designated 78 that provide sensor signals and datainput to the processor 60. The processor 60 utilizes these sensorsignals and data inputs for various purposes and signal generation asdiscussed herein. The washing machine 5 also includes a control input 76that represents user-actuated inputs. Signals from the control input 76are forwarded to the processor 76. The sensor/data input 78 and/or thecontrol input 76 provides data to the processor 60 that the processor 60may use to generate the control signal for the power control system 14.

In addition to the various components, features and/or functionsdescribed in conjunction with FIG. 3, the power control system 14includes clamp circuitry/logic 74 that is provided in conjunction withthe standby/low power circuitry/logic 64. The clamp circuitry/logic 74is operative to set and the power level of the standby/low powercircuitry/logic 64 or prevent over power of the standby/low powercircuitry/logic 64.

It should be appreciated that various components of the washing machine5, such as the motor 26, utilize the line electricity (typically 120volts or 240 volts) for operation. This is not the same as the operatingpower generated by the operating power circuitry/logic. The washingmachine 5 utilizes the operating power for actuation of the variousrelays, solenoids, and the like. These relays, solenoids, and the like,actuate the motor, water valves, and other like components of thewashing machine 5 of which some then utilize the line electricity foroperation. Additionally, the line electricity is utilized in conjunctionwith various switches, such as safety switches (e.g. the lid switch 28),that provide a signal to the processor 60 regarding the state of theparticular switch. Where necessary, these switches and the like areexplained in detail herein.

As indicated above, the operating power from the operating powercircuitry/logic 66 is applied or supplied to the operating powercomponents 52 through the switching circuitry 68, with the switchingcircuitry 68 controlled by a control signal or control signals from theprocessor 60. In one form, the switching circuitry 68 includes signalconditioning circuitry/logic 80 that receives the control signal via thecontrol signal line 70 from the processor 60. The switchingcircuitry/logic 68 also includes a silicon controlled rectifier (SCR) 82(or any other similar operating/functioning device) that is incommunication with the signal conditioning circuitry/logic 80 and withthe operating power circuitry/logic 66. The SCR 82 is thus operative toswitch in or allow the operating power from the operating powercircuitry/logic 66 to be applied or supplied to the various operatingpower components 52 (run mode) upon being triggered (receiving) theconditioned control signal from the signal conditioning circuitry/logic80. The processor 60 produces a control signal that is provided to thesignal conditioning circuitry/logic 80 and then to the SCR 82 when it isappropriate for the operating power to be supplied to the operatingpower components. Particularly, the processor 60 provides the controlsignal when the user actuates the washing machine 5 into a run mode(selects a run mode cycle or the like of the washing machine 5). The SCR82 thus switches in or allows the switching in of the operating powerinto the circuitry/logic of the washing machine 5.

Because the operating power is needed when the appliance is started(i.e. the run mode), a start/stop signal, represented by the start/stopblock 158, is provided to the controller 158 for use in producing thecontrol signal and providing the control signal to the SCR 172. Thestart/stop signal is preferably provided through the operational modeindicator/cycle indicator of the laundry appliance. As well, othercomponents of the laundry appliance, represented by the component inputblock 156, may provide a signal or signals for use in producing thecontrol signal.

In one form, the processor 60 continues to provide a control signal tothe signal conditioning circuitry/logic 80 during any run mode cycle ofthe washing machine 5 or while operating power is required. The signalconditioning circuitry/logic 80 thus continues to provide the controlsignal to the SCR 82 in like manner and the SCR 82, in turn, stays on tokeep the operating power from the operating power circuitry/logic 66 tothe operating power components 52.

Alternatively, in another form, the processor 60 provides a controlsignal to the signal conditioning circuitry/logic 80 that stops theapplication of a conditioned control signal from the signal conditioningcircuitry/logic 80 to the SCR 82. The SCR 82 is thus responsive to the“off” control signal to shut off the application of the operating powerfrom the operating power circuitry/logic 66 to the operating powercomponents 52.

Referring now to FIG. 5, there is shown a specific exemplary embodimentof a power control system 14 in accordance with the present principles.The power control system 14 of FIG. 5 is shown in electrical schematicform. The power control system of FIG. 5 operates and/or functions inthe manner set forth above.

The power control system 14 receives incoming electricity from a Line Inelectricity source. Particularly, line electricity (hot) from anelectricity source (e.g. a wall plug) is provided at P14, terminal 1,wherein it is provided to other components via the terminal 84 (“L”).Neutral is coupled at P14, terminal 2, where neutral is equated withground. A variable resistor VR1 of sufficient resistance and voltagerating is provided between the line electricity and the neutral forshort circuit protection.

The line cross circuitry/logic 62 is coupled to the line electricity forproviding a line cross signal R on line 86. Line 86 is in communicationwith the processor 60 (not shown in FIG. 5). The line crosscircuitry/logic 62 includes a transistor Q14 that is biased by the lineelectricity such that the collector (terminal 3) provides the line crosssignal. As mentioned above, the line cross signal R is utilized by theprocessor 60 to indicate phase of the line electricity. The line crosssignal is also utilized by the processor for clocking purposes. Inparticular, the transistor Q14 (an NPN transistor) is alternativelyswitched on and off by the alternating current of the line electricityto provide the line cross signal R at line 86.

The power control system 14 includes a bank of capacitors 88 that are incommunication with and charged by the line electricity. In accordancewith an aspect of the present invention, only one of the capacitors, C7,however, is normally dischargeable after charging, since the terminal(terminal 1) that is opposite the terminal (terminal 2) that is incommunication with the line in electricity, completes a circuit.Particularly, the capacitor C7 is dischargeable through the diode D5 anda five (5) volt power supply circuitry/logic formed, in part, by thediode D1 and the capacitor C4. This forms the standby/low powercircuitry/logic 64. The standby/low power circuitry/logic 64 may includemore than one capacitor (C7) if desired or necessary.

The standby or low power circuitry/logic 64 is thus always operativewhen the washing machine 5 is plugged into the line electricity.Clamping circuitry 74 is provided in communication with the standby/lowpower circuitry/logic 64 to keep the standby/low power circuitry/logic(the five volt power circuitry/logic) at a constant voltage level.

While the other capacitors C12 and C13 of the capacitor bank 88 normallycharge, they are not normally able to discharge, and thus form anormally open circuit. The SCR 82, however, is provided that isoperative to provide a discharge path for the capacitors C12 and C13upon the application of a control signal to the SCR 82. The controlsignal is provided via control line 70 from the processor 60 to thecontrol signal conditioning circuitry/logic 80. The control signal isthen applied to the gate (terminal 2) of a transistor Q6 (a PNPtransistor) of the control signal conditioning circuitry/logic 80wherein a control signal is taken from the collector (terminal 3) andapplied to the control input (terminal 2) of the SCR 82.

When the SCR 82 is turned on (allowed to conduct) by the application ofthe control signal from the transistor Q6, a discharge path is createdfor the capacitors C12 and C13. The capacitors C12 and C13 dischargethrough the diode D9 that, together with capacitor C10, provides arectified (DC) operating voltage of twenty-four (24) volts., This, inpart, constitutes the operating power circuitry/logic 66. Thus, onlywhen a control signal is applied to the circuitry/logic, does theoperating power become applied/supplied to the proper components of thewashing machine 5.

It should be appreciated that operating power circuitry/logic 66 mayinclude any number of capacitors as desired or necessary. Further, itshould be appreciated that the various values of resistors andcapacitors of the power control system 14 are subject to modification asdesired.

With reference to FIG. 6, an exemplary manner of operation of thepresent power control system will be described in conjunction with theflowchart thereof, the flowchart generally designated 90. Initially, thewashing machine is plugged into a source of suitable electricity (lineelectricity), step 92. This is typically a wall outlet (not shown) of ahome, business, or the like such as is known that supplies 120 or 240volt AC power. When the power control system is receiving lineelectricity, the phase of the line electricity is monitored, step 94.The power control system monitors the phase of the line electricity forclocking purposes of and the like.

The washing machine monitors and/or determines if the washing machine isto be or is in an idle mode or a run mode, step 96. If in the idle mode,the power control system generates idle mode (low) power, step 98. Theidle mode power is provided to the idle mode (low/standby) powercircuitry/logic, step 100. The power control system continues togenerate and provide idle mode power as long as the washing machine isplugged in, step 102.

In step 96, if the washing machine is or is to be in a run mode, thepower control system generates run mode (operating) power, step 104, andgenerates idle mode (operating) power 98 (and additionally performssteps 100 and 102). In step 106, the generated run mode power isprovided to the run power components. The power control systemdetermines whether a stop signal has been produced or not, step 108. Ifa stop signal has been produced, then run mode power is ceased, and thepower control system/washing machine returns to the idle/run modedecision step (step 96), step 110. If a stop signal has not beenproduced, then run mode power is generated (back to step 104) until astop signal is produced.

With respect to the operation of the power supply, idle mode power ispreferably always generated when the washing machine is plugged in. Thisallows the integrated circuits and the like to be powered up forclocking and other purposes. Not all of the integrated circuits maynecessarily be provided idle mode (standby or low) power. Further, runmode (operational) power is typically provided only when the washingmachine is turned on by the user (a run mode or cycle is chosen).

Auxiliary Inputs

As seen in FIG. 1 the appliance control system (ACS) 10 of the washingmachine 5 has a plurality of auxiliary input units 44. Each auxiliaryinput unit 44 is operative to allow the selection or adjusting ofvarious parameters of and/or related to the washing machine 5. Inparticular, the auxiliary input units 44 allow a user to select variousoptions or parameters for the operating mode of the washing machine (theoperating mode being separately selected by the user via the maincontroller module 300 of the ACS 10. The options may be watertemperature, rinse options, load size, speed, fabric type, or the likedepending on the particular make and/or model of the washing machine.

Referring now to FIGS. 7 and 8, there is shown a representation of theplurality of auxiliary inputs or input units, generally designated 44 ofthe ACS 10. In accordance with an aspect of the present invention, theplurality of auxiliary input units 44 are connected in series, with afirst auxiliary input unit 112 coupled to and in communication with anauxiliary input port 114 of the ACS 10. Since the auxiliary input units44 are typically mounted on the control panel 40 (see FIG. 1) theauxiliary input units 44 are remote from the majority of the electroniccircuitry/logic of the ACS 10. The majority of the electroniccircuitry/logic of the ACS 10 is thus provided on one or just several PCboards. Providing a port on one of the PC boards, provides a convenientway to coupled the auxiliary input units 44 to the remainder of theelectronic circuitry/logic of the ACS 10.

An output of the first auxiliary input unit 112 is coupled to theauxiliary input port 114 and thus in communication with the processor 60via two wires or conductors 122 and 124. An output of a second auxiliaryinput unit 118 is coupled to and in communication with an input of thefirst auxiliary input unit 112 via two wires 126 and 128. Anyintermediate or middle auxiliary input units (not shown but representedby “•••” in FIGS. 7 and 8) are likewise coupled to and in communicationwith a previously adjacent auxiliary input unit. The last auxiliaryinput unit 120 is coupled to and in communication with the intermediaryauxiliary input units via two wires 130 and 132. The series connectionof auxiliary input units 44 form a daisy-chain and, more particularly, atwo-wire daisy-chain or serial connection. Any amount of auxiliary inputunits 44 is thus daisy-chainable.

Each auxiliary input unit 112, 118, and 120 has a respective knob, dial,or the like 134, 136, and 138. The knobs 134, 136, and 138 allow for theuser-selection of the various adjusting parameters of the appliance. Theknobs may be discrete, position type switches or may be variableposition controls. In either case each knob 134, 136, and 138 allows auser to select a position that corresponds to a particular option of twoor more possible options. Typically one auxiliary input unit isdedicated to a particular option such as water temperature. As anexample and referring to FIG. 7, the auxiliary input unit 120 has twouser-selectable options, positions, or settings labeled A and B. Theindicator (arrow) on the knob 138 points to selection A. In accordancewith an aspect of the present invention, position A has a uniqueparameter value associated therewith, while position B also has a uniqueparameter value associated therewith. The unique parameter value of theposition or setting of the knob 138 (or the auxiliary input unit 120) isprovided as a parameter value signal to the adjacent auxiliary inputunit, here the auxiliary input unit 118). The auxiliary input unit 118has three user-selectable options, positions, or settings labeled C, D,and E. Each position C, D, and E has a unique parameter value associatedtherewith. In accordance with an aspect of the present invention, theunique parameter value of the position or setting of the knob 136 (orthe auxiliary input unit 118) is combined with the unique parametervalue of the auxiliary input unit 120 and provided as a combinedparameter value signal to the adjacent auxiliary input unit closest tothe auxiliary input port 114, here the auxiliary input unit 112). Theauxiliary input unit 112 has three user-selectable options, positions,or settings labeled F, G, and H. Each position F, G, and H has a uniqueparameter value associated therewith. In accordance with an aspect ofthe present invention, the unique parameter value of the position orsetting of the knob 134 (or the auxiliary input unit 112) is combinedwith the combined unique parameter value of the auxiliary input units120 and 118 and provided as an aggregate parameter value signal to theauxiliary input port 114, and thus the processor 60. The processor 60,under control of program instructions contained in the memory 116analyzes the aggregate parameter value signal to determine theparticular option selected for each auxiliary input unit. The uniqueaggregate parameter value is thus used to determine the parameter valuefor each auxiliary input unit 44. Once the particular parameter value isknown for each auxiliary input unit 44, the particular option or settingfor each auxiliary input unit is known.

Referring particularly to FIG. 8, the plurality of auxiliary input units44 are shown in side view. Each knob 134, 136, and 138 is connected to arespective shaft 140, 142, and 144 that is retained in a respective body146, 148, and 150. Each knob and shaft combination, 134/146, 136/148,and 138/150 is rotatable relative to its respective body 146, 148, and150. Additionally each knob/shaft combination, 134/146, 136/148, and138/150 includes a respective detent plate 152, 154, and 156. Eachdetent plate 152, 154, and 156 is fixed relative to its respectiveknob/shaft combination, 134/146, 136/148, and 138/150. Each knob 134,136, and 138 includes a plurality of grooves or notches on an undersidethereof such that the knob and detent plate combinations 134/152,136/154, and 138/156, co-act with one another during rotation of theknob/shaft combination, 134/146, 136/148, and 138/150. This provides atactile feedback for a user during rotation thereof.

In FIGS. 10-12, there is depicted electrical schematics of an embodimentof a portion of the ACS 10. In FIG. 10, the processor 60 of the ACS 10is shown as a Hitachi HB/3664 microcontroller (labeled U1), but whichcan be any suitable processor or processor unit. The various electricalcomponents and connections to the processor 60 are shown. For instance,a clocking circuit 158 is depicted that provides clock signals for theprocessor 60, wherein the OSC 1 of the clock circuitry 158 is coupled topin 11 (OSC1) and the OSC 2 of the clock circuitry 158 is coupled to pin10 (OSC2).

In FIG. 11, the auxiliary input port 114 is formed of a first channelinput labeled P2, terminal 1, and a second channel input labeled P2,terminal 2. The first and second channels receive as inputs the twowires (122 and 124) of the first auxiliary input unit 112. Preferably,the first and second input terminals are in the form of a receptaclethat is adapted/configured to receive a mating plug as a termination ofthe two wires 122 and 124. A third terminal, labeled P2, terminal 3, maybe provided as part of the receptacle and is coupled to electricalground. In this case, a third wire may be provided from each auxiliaryinput unit, or as one conductor of a two conductor wire from theauxiliary input unit. The first and second channels, P2 terminal 1 andP2 terminal 2 are coupled to or in communication with the processor 60in order to provide the aggregate parameter value signal to theprocessor 60 from the auxiliary input units 44.

In FIG. 12, the memory 116 that stores the program instructions for theACS 10 and the washing machine 5 in general, includes a serial data lineinput/output, labeled SDA (pin 5) for communication with the processor60 and a serial clock line input, labeled SCL (pin 6) for receipt ofclocking signals from the processor 60. In this manner, the programinstructions may be transferred to the processor 60, while the memory116 may also be written to by the processor 60. In accordance with anaspect of the present invention that is described in greater detailbelow, the memory 116 is operative to be erased and to store new programinstructions, particularly via a communications port. The memory 116thus provides the program instructions to the processor 60 for resolvingthe parameter value signal into a command signal for application of theappropriate features in accordance with the user-selected adjustingparameters.

Each auxiliary input unit 112, 118, and 120 provides a signal regardingthe angular or rotational position of the respective knob and shaft134/140, 136/142, and 138/144 relative to its respective body 146, 148,and 150 that is communicated to the processor 60 via the auxiliary inputport 114. The rotational or angular position of each knob/shaft 134/140,136/142, and 138/144 relative to its respective body 146, 148, and 150of the respective auxiliary input unit 112, 118, and 120 determines aparticular parameter or option selection of various parameter or optionselections for the particular auxiliary input unit. Such also produces aunique aggregate parameter value signal. The processor 60, under controlof programming instructions retained or stored in the memory 116, isoperative to determine each auxiliary parameter selection based on theparticular parameter value signal generated or produced by therotational or angular position of the knob/shaft 134/140, 136/142, and138/144 relative to its respective body 146, 148, and 150. The processor60 then uses this information to perform the particular functionaccording to the selection.

Referring to FIG. 9, an embodiment or implementation of auxiliary inputunits 44 in accordance with the above is shown. In one form, eachauxiliary input unit 112, 118, and 120 may be or form a variableresistor (respectively variable resistors 160, 162, and 164) whereinresistance is the parameter value. The auxiliary input units 112, 118,and 120 may thus be low power potentiometers. It should be appreciated,however, that the type of device that yields a parameter value in thesame or similar manner as that described above may be used. In the caseof the variable resistors 160, 162, and 164, the angular or rotationalposition of a knob/shaft 134/140, 136/142, and 138/144 produces adifferent resistance value for the respective auxiliary input unit. Theauxiliary input units 44 cooperate with each other to produce a uniqueaggregate resistance value or signal for the particular arrangement ofuser knobs of the auxiliary input units 44. This unique resistancesignal is received by the processor 60 thereby providing user selectioninformation relating to the various auxiliary input units 44 to theprocessor 60. The processor 60 utilizes the program instructions in thememory 116 to determine the setting for each auxiliary input unit basedon the aggregate resistance signal, wherein the setting defines theselected option. The range of resistance values of the variableresistors or potentiometers are selected appropriately such thatcalculations may be performed on the aggregate resistance signal toyield the rotational or angular positions of the knobs/shafts whichdetermined the user selection of adjusting parameters for the appliance.

With reference to FIG. 13, there is depicted a flowchart, generallydesignated 170, of an exemplary manner of operation or use of theauxiliary input units 44. In step 172, there is selection of applianceoptions or settings for a particular mode or cycle of operation by auser. This is accomplished by rotating the knob, dial, switch, or thelike of each auxiliary input unit to a particular position correspondingto a desired option or setting. Depending on the appliance, theauxiliary input units correspond to different options. Once the variousoption settings have been selected via the auxiliary input unit(s), eachauxiliary input unit produces a parameter value. The parameter values ofall of the auxiliary input units are combined such that an aggregate andunique combination of parameter values are produced by the auxiliaryinput units. In step 174, the processor or controller obtains thisaggregate parameter value or signal. The processor may obtain theaggregate parameter value when it is appropriate. A typical appropriatetime is when the washing machine (appliance) is turned on or after thewashing machine is turned on and during a time when the parameters wouldaffect appliance operation or function.

In step 176, the processor then calculates the position of the variousauxiliary input units based on the aggregate parameter value/signal.Since the washing machine knows the number of auxiliary input units andthe range of parameter values each auxiliary input unit can assume, theaggregate parameter value/signal correlates to knob (rotation orangular) position of the auxiliary input units that corresponds to theselected options. Thereafter, in step 178, the washing machine performsthe option selections at the appropriate time.

Hyperspin Mode

In accordance with another aspect of the present invention, the washingmachine 5 (see FIG. 1) is operative to provide a hyperspin mode ofoperation during a drying cycle or mode of the washing machine 5 whenappropriate. Particularly, the motor 26 of the washing machine 5 isoperative in two speeds, namely, a normal or first speed and a hyper orsecond speed. Since the motor 26 is coupled to the receptacle 32 suchthat the motor 26 rotates or spins the receptacle 32, the motor 26 isoperative to rotate or spin the receptacle up to the limit of the firstspeed and up to the limit of the second speed. It should be appreciatedthat the term “up to” is used to denote that even though the motor 26 isoperative to rotate at two speeds in accordance with the application ofa known, steady power, various factors may prevent the receptacle 32from being rotated at the same or maximum first or second speeds of themotor 26. These various factors may be measured as parameters of thereceptacle 32 during either at rest and/or during rotation thereof.

The first speed corresponds to a traditional spin dry cycle mode of thewashing machine 5, while the second speed corresponds to the presenthyperspin mode wherein the receptacle 32 is spun at a speed that isgreater than the first speed. A typical first speed is around 600 RPMsTo prevent damage to the washing machine 5 as a result of spinningheavier, unbalanced loads at the second speed, a processor or controllerdetects various parameters of receptacle 26 and/or the washing machine 5while the receptacle 32 is spun at the first speed. If the detectedparameters are at or within acceptable parameter levels or ranges, theprocessor 60 operates to cause the motor 26 to rotate the receptacle 32at the second speed (higher or hyper speed) thereby resulting in removalof more water from the contents of the laundry in the receptacle 32 thanat the first speed (traditional speed). An eximplary second or hyperspeed is around 800-850 RPMs, but may be only around 700 RPMs dependingon the washing machine type.

Referring to FIG. 14, there is depicted a block diagram of the washingmachine 5 that is operative to provide the present hyperspinfeature/function in accordance with the present principles. The washingmachine 5 is shown with the receptacle 32 for receiving laundry to wash.The receptacle 32 is adapted to rotate or spin up to a maximum firstspeed and up to a maximum second speed, with the second speed beinggreater than the first speed. The receptacle 32 is coupled to the motor26 that is operative to spin the receptacle at a first and second speed.

It should be appreciated that the hyperspin aspect of the presentinvention relates to the drying cycle or mode of the washing machine 5.The receptacle 32 is typically agitated during washing modes or cyclessuch that the receptacle 32 rotates in one direction then another(clockwise and counterclockwise) in short, successive cycles. When thewashing machine 5, however, is in a drying mode or cycle (i.e. thewashing machine is trying to remove as much excess water from thelaundry), the receptacle 32 is spun by the motor 26 in a singlerotational direction (clockwise or counterclockwise). The motor 26rotates the receptacle 32 at the first speed during the normal ortypical drying mode or cycle. It will be assumed that the washingmachine 5 is in the drying mode or cycle for purposes of the presenthyperspin discussion.

The motor 26 is under control of the processor 60. The processor 60utilizes program instructions stored in the memory 116 to perform thepresent hyperspin feature. The washing machine 5 further includes areceptacle parameter detector 180. The receptacle parameter detector 180is coupled to or in communication with the receptacle 32, represented bythe line 181, and/or the washing machine 5 itself (in which case thereceptacle parameter detector functions as a washing machine detector.The receptacle parameter detector 180 is operative to receive or senseparameter data regarding the receptacle 32 and/or the washing machine 5in general, generate a signal or signals representative of the sensedand/or detected parameter data, and forward the sensed and/or detectedreceptacle parameter data signal(s) to the processor 60. The receptacleparameter detector 180 provides receptacle parameter data signals to theprocessor 180 during operation of the washing machine 5 but may alsoprovide correlating data when the washing machine 5 is not in use orduring operational cycles other than the drying cycle. The processor 60utilizes the receptacle parameter data signals to determine an operatingstate of the washing machine 5 in general and/or of the receptacle 32.The receptacle parameter detector data signals present values or levelsof parameter data either on a discrete basis and/or on a continuousbasis.

The motor 26 is operative during the drying cycle to rotate at the firstspeed to rotate the receptacle 32 up to the particular first speed.During this time, the processor 60 receives receptacle parameter datasignals from the parameter detector 180. If the parameter data signalsare less than a predetermined threshold value or level or within apredetermined threshold range, the motor 26 is caused to run at a secondor hyper speed that is greater than the first speed. As an example ofthe above, the second or hyper speed of the receptacle 32 is 25% greaterthat he first speed of the receptacle 32. Thus, the receptacle 32 iscaused to rotate up to the second or hyper speed. The parameter datasignals are monitored to determine if the parameter exceeds thepredetermined threshold level or is outside the threshold range in orderto cause the motor 26 to return to the first speed and thus rotate thereceptacle 32 down to the first speed as a maximum. This may be repeatedas appropriate during the drying cycle of the washing machine 5.

In FIG. 15, there is depicted a more detailed block diagram of thewashing machine 5 in accordance with the principles presented herein. InFIG. 15, the washing machine 5 includes control circuitry/logic 182 thatis in communication with the processor 60 and a two-speed motor 26 athat is in communication with the control circuitry/logic 182. Thetwo-speed motor 26 a is operative to rotate at two distinct speedscorresponding to the first speed and the second, hyper speed. In turn,the receptacle 32 is rotatable by the two-speed motor 26 a up to themaximum rotation velocity of the first and second speeds. The maximumrotation speeds of the receptacle 32 are limited by the maximum rotationspeeds of the motor 26 a and various parameters or conditions of thereceptacle such as load amount and load balance. The motor 26 a receivessignals from the control circuitry/logic 182 that receives controlsignals from the processor 60, specifically to actuate the motor 26 aaccordingly to put the motor 26 a into the first or second speeds, orenergize appropriate windings of the motor 26 a that are responsible forthe two speeds. Again, the memory 116 stores program instructions thatare provided to the processor 276 as appropriate. The washing machine 5includes the receptacle parameter detector 180 that is in communicationwith the receptacle 32 and/or the washing machine 5. The receptacleparameter detector 180 is operative to obtain data regarding variousconditions or parameters of the receptacle 32 and/or the washing machine32, most particularly during the drying cycle of the washing machine 5.The condition/parameter data is forwarded to the processor 60 that isoperative via program instructions stored in the memory 116 to analyzethe condition/parameter data and provide outputs to various othercomponents and/or circuitry/logic as appropriate. This is to determinewhether receptacle conditions are favorable to spin the receptacle 32 atthe hyperspin speed.

Referring to FIG. 16, there is depicted a more detailed block diagram ofthe washing machine 5 and, in particular, the control circuitry/logic182. The control circuitry/logic 182 includes a first speed switch orswitching circuitry/logic 184 and a second speed switch or switchingcircuitry/logic 186 each of which is under control of the processor 60.The first speed switch 184 is operative to cause the two-speed motor 26a to operate in or at the first speed. The second speed switch 186 isoperative to cause the two-speed motor 26 a to operate in or at thesecond speed, wherein the second speed is greater than the first speed.Particularly, the second speed is the hyperspin speed for the receptacle32. The washing machine 5 also includes the door switch 28 that isoperative to cut power to or turn off the motor 26 a when the lid ordoor of the washing machine is opened or open.

The door switch 28 is in communication with the lid 34 of the washingmachine 5 (see FIG. 1) such that the lid 34 must be closed before themotor 26 a will operate. When the lid 34 is closed the switch allows themotor 26 a to operate. When the lid 34 is open the switch prevents themotor 26 a from operating. It does not matter whether the switch 34 isnormally open or closed. In this manner, the door switch 34 provides asafety mechanism. Additionally, the state of the door switch 34 ismonitored by the processor 60 such that other functions and/or featuresof the washing machine 5 may be at least temporarily halted when the lid34 is open, and then possibly restarted when the lid 34 is closed.

The receptacle parameter detector 180 may take several forms dependingon the parameter or condition that is to be monitored. In one form,vibration or wobble of the receptacle 32 may be monitored. In anotherform, the rotation speed or velocity of the receptacle 32 may bemonitored. Load amount (weight) and/or load distribution may also betaken into account. Of course, other parameters or conditions of thereceptacle 32 may be detected, monitored, or measured. It should beappreciated that the parameter detector 180 represents one or more ofthe various forms of detecting, monitoring, and/or measuring conditionsand/or parameters of the receptacle 32 and/or the washing machine 5.Likewise, it should be appreciate that the term parameter alsoencompasses a condition, state, mode, characteristic, manner, or thelike.

The receptacle 32 (and/or washing machine 5) is monitored via one ormore of the above forms in order to detect imbalance during the dryingcycle (rotation), particularly or initially at the first speed.Imbalance of the receptacle 32 relative to a central vertical axis ofthe receptacle 32 as a result of an imperfect laundry load distributionwithin the receptacle 32, can cause undue stresses and strains on thesystem. Since the drying cycle spins the receptacle 32 at a fairly highrate or revolutions per minute, the monitoring of the receptacle isappropriate before an even higher rate of speed (hyperspin) is attemptedor attained. If the receptacle is rotating within an acceptableparameter threshold range or at or below a parameter threshold value,the hyperspin mode will be attained, else the motor will remain at thefirst speed. As well, continuous monitoring is appropriate at the firstspeed if hyperspin fails to determine if hyperspin can later be achievedwithin the remaining drying time and after the hyperspin mode isachieved in order to detect is an off balance condition develops. If anoff balance condition develops during the hyperspin mode, the motor willbe put back to the first speed. The imbalance or off balance condition,if any, of the receptacle 32 during rotation should therefore bemonitored to avoid mechanical problems.

Vibration may be monitored utilizing a vibration sensor or sensorsstrategically placed on and/or around the receptacle 32. The processor60 monitors vibration data from the vibration sensors. Particularly, theprocessor 60 under the control of program instructions stored in thememory 116, monitors the vibration data during the normal dryingoperation. If the vibration data indicates that the vibration is at orbelow a threshold vibration value or level, or within a threshold range,the processor 60 will send an actuation signal to the second speedswitch 186. The actuation signal will cause the second speed switch 186to put the two-speed motor 26 a into the second speed (hyperspin) suchthat the receptacle 32 will be rotated up to the second speed. Theprocessor 60 continues to monitor the vibration data from the vibrationsensor(s) during the hyperspin mode.

The vibration data from the vibration sensor(s) indicates generally theload/balance state of the receptacle 32. In particular, if the laundrywithin the receptacle 32 is well balanced during the first speed, therewill be little to no vibration produced during the first speed spin ofthe receptacle 32. If, however, the laundry within the receptacle 32 isnot well balanced during the first speed spin of the receptacle 32,there will be vibration of a greater degree than with a more balancedload. The degree or level of vibration must be acceptable (i.e. at orbelow a threshold vibration level, or within a threshold vibration levelrange) before the processor 60 actuates the second speed switch 186 thatcauses the motor 26 a to spin the receptacle 32 at the hyperspin speed(alternatively, if the level of vibration is unacceptable, the processor60 will not actuate the second speed switch 186 that makes the motor 26a to enter the hyperspin mode).

Rotation speed or velocity of the receptacle 32 may also be monitored,detected, or measure either from the receptacle itself, a rotation shaftof the receptacle 32 or otherwise. This may be accomplished via a halleffect sensor and a magnet, a light beam transmitter/detector, a shaftencoder, or the like. In the case of receptacle rotation speeddetection, in the ideal situation or case, the receptacle 32 can onlyrotate at the maximum speed of the motor. A deviation of speed in thedownward direction (less than the maximum) rotation speed indicates aload imbalance. Typically, however, the receptacle will not ideallyachieve the maximum rotational speed or velocity of the motor either atthe first or second speed. It will be somewhat less even with a“perfectly” balanced laundry load. In other words, rotation speed of thereceptacle will typically be somewhat slower than the maximum of theideal motor speed. Thus, the rotational velocity of the receptacle 32will be monitored, detected, or measured to determine if the rotationalspeed or velocity of the receptacle is above a threshold rotation speedvalue or within an acceptable rotation speed range. If the rotationalspeed of the receptacle 32 is above the threshold speed value or withinthe acceptable threshold speed range, the processor 60 will cause thesecond speed switch 186 to actuate causing the motor 26 a to go into thehyperspin mode (second speed). As well, the parameter detector 180 willprovide continuous monitoring, detecting, and/or measuring of therotational speed to determine if all is well or if the motor should betaken back to the first speed.

As an example of using rotational speed of the receptacle as theparameter data a first speed may be approximately 600 RPMs, while asecond speed may be 800 RPMs. A threshold level at which the secondspeed is started may be no less than 80% of the first speed (i.e. thereceptacle 32 must rotate between 80%-100% of the first speed). If thereceptacle 32 is rotating at less that 80%, hyperspin will not be used.Likewise, when the washing machine 5 is in the hyperspin mode (in secondspeed) the rotation velocity of the receptacle may not be less than 80%of the second speed in order to maintain the hyperspin mode. Areceptacle speed less than 80% of the second speed would cause thewashing machine to go back into the first speed

In FIGS. 17 and 18 there is depicted an electrical schematic of aportion of an embodiment of a washing machine having the presenthyperspin feature. The two-speed motor 26 a includes a start winding 194that is connected in series with a centrifugal switch 192. The startwinding 194 and the centrifugal switch 192 are coupled between terminalsP10 and P12. The terminals P10 and P12 are coupled to or incommunication with respective relays 196 and 197. The relays 196 and 198and are adapted to couple the start winding 194 and the centrifugalswitch 192 to line electricity (via the door switch 28 when closed) andneutral. The relays 192 and 194 are actuated via a transistor Q10(electronic switch) and associated control/conditioning circuitry/logicthat receives an actuation signal from the processor 60. Control signalsfrom the processor 60 provide actuation of the relays 196 and 198through the transistor Q10. The start winding 194 is actuated when amain power relay 200, actuated via a transistor Q8 (electronic switch)and associated control/conditioning circuitry/logic, couples the lineelectricity from the door switch 28 into supply line 202. When the motor26 a reaches a running speed (less than or equal to the first motorspeed), the centrifugal switch 192 open circuits the start winding 194from the motor 26 a.

At the same time the main relay 200 is providing line electricity to thestart winding 194, line electricity is also provided to either of afirst main winding 188 or a second main winding 190. Selection of whichwinding receives the line electricity is controlled via a relay 204 thatreceives an actuation signal via a transistor Q11 (electronic switch)and associated control/conditioning circuitry/logic. It should beappreciated that the various switching circuitry/relays of FIG. 17receive actuation signals from the processor 60. The first winding 188is adapted to allow the motor 26 a to achieve a first speed, while thesecond winding 190 is adapted to allow the motor 26 a to achieve asecond speed. In accordance with the present principles, the secondspeed is greater than the first speed and is termed hyperspin speed. Themain relay 200 thus controls the application of line electricity throughthe door switch 28 to either the first or second winding 188 or 190.

The door switch 28 is coupled at one electrical side or terminal to lineelectricity, while the other electrical side or terminal is coupled toterminal P6. The terminal P6 is in communication with the processor 60via a monitoring line or conductor 202. The door switch 28 is positionedrelative to the lid 34 of the washing machine (see FIG. 1) such that thedoor switch 28 provides a signal to the processor 60 so that theprocessor 60 can monitor whether the door switch 28 (i.e. the appliancedoor or lid) is open or closed (corresponding to the state of the lid ofthe washing machine). The monitoring line 202 is also in communicationwith the main relay 200. In this manner, even if the main relay 200 isin an on state (supplying line electricity to the first or second motorwinding 188, 190), when the door switch 28 is open (the door or lid ofthe appliance is open) the power to the motor 26 a is shut off (i.e. theline electricity will not flow through the relay 616). This provides asafety switch to shut power to the motor 26 a.

Referring to FIG. 19, there is depicted a flowchart, generallydesignated 210, of an exemplary manner of operation of the presenthyperspin feature or function. In step 212 the washing machine is putinto or reaches a laundry drying cycle, stage, or mode. In step 214, themotor or motive power producer is actuated into a first speed to causethe laundry receptacle of the washing machine to spin or rotate up tothe first speed. During rotation of the laundry receptacle up to thefirst speed, receptacle parameter data is obtained, step 216. Thereceptacle parameter data may be obtained from vibration sensorspositioned to obtain vibration data from the receptacle and/or thewashing machine in general, from rotation velocity detectors positionedto obtain rotational velocity data from the receptacle or as part of thereceptacle or receptacle rotation shaft, or from other detectors,transducers, or the like that are operative to detect or measure otherreceptacle parameter data.

In step 218, the obtained receptacle parameter data is analyzed.Particularly, the processor analyzes the obtained receptacle parameterdata under control of program instructions (software) stored in thememory. The processor analyzes the receptacle parameter data todetermine if the receptacle is not balanced (i.e. the laundry load isnot distributed well therein causing an imbalance). More particularly,in step 220, the receptacle parameter data is analyzed to determine ifthe particular parameter or parameters the washing machine/receptacleare below a predetermined parameter threshold level or value, are withina particular parameter threshold range, or are above a predeterminedparameter threshold level or value, depending on the particularparameter. The predetermined threshold or level is selected such that ifa higher speed is applied to the rotation of the receptacle, there willbe little to no damage as a result of the second speed.

In step 220, if the receptacle parameter is outside the appropriate orpredetermined threshold value or range, the motor 26 is caused to remainat the first speed (and thus the receptacle as well) and the flow goesback to step 216. There is also a check to see if the dry cycle is at ornear the end, and if so, the flow ends, step 222. However, if thereceptacle parameter is within the appropriate or predeterminedthreshold value or range, the motor is actuated into the second,hyperspin speed and the receptacle as well, step 224. Thereafter thereis a continuation of monitoring, step 226. Periodically, the flowreturns to step 220.

Wiper Assembly and Mode Control

The mode switch 378 has two positions that define two modes of operationof the main controller module 300 namely, a user cycle selection modeand a cycle operation mode. In the user cycle selection mode, the usercycle selector is rotated by the user in order to select a particularoperating cycle of the washing machine 5 (i.e. a selected appliancecycle). Referring to FIG. 53, there is shown various exemplary operatingcycles, such as permanent press, knit delicate, pre-wash, cotton, andrinse & spin printed on an overlay 388 adjacent the LEDs. Of course,other and/or different cycles may be provided as desired. Duringrotation of the user cycle selector, individual LEDs 307 (represented bythe triangles) are alternately lit depending on and in accordance withthe direction of rotation of the user cycle selector and the speed ofrotation. The processor 60 generates position signals for the individualLEDs 307 depending on the direction of rotation of the user cycleselector and the rate of rotation. The position signals are used tolight and turn off the appropriate LEDs. As the user cycle selector isrotated, the appropriate or next LED is lit while the previously lit LEDis turned off. Once a desired cycle or position within a cycle isselected (i.e. the appropriate LED is lit), the user puts the washingmachine 5 into the cycle operation mode by pushing the control knobinwardly toward the overlay 388.

Referring to FIGS. 47 and 50, the translation of the rotation of theuser cycle selector and/or generation of the position signals when themain controller module 300 is in the user cycle selection mode will bediscussed. The wiper 336 and the circuit pattern assembly 338 cooperateduring rotation of the carrier member 334 (which is part of user cycleselector assembly) to provide user cycle selection signals and/orposition signals (for lighting the appropriate LEDs and to indicate tothe processor the cycle and the particular position status within thecycle) to the processor 60 when the mode switch 378 is in a user cycleselection mode.

The wiper 336 includes three fingers 380, 382, and 384. The inner finger380 is a voltage source terminal that receives a voltage from thecircuit pattern assembly 338. The middle finger 382 is arbitrarily afirst state terminal that conducts the voltage from the inner finger 380to the processor 60 when appropriate. The outside finger 384 isarbitrarily a second state terminal that conducts the voltage from theinner finger 380 to the processor 60 when appropriate.

The circuit pattern assembly 338 includes a voltage trace or conductor390 that terminates in a terminal 396 that is coupled to a voltagesource. The circuit pattern assembly 338 also includes a first statetrace or conductor 392 of a zigzag pattern that terminates in a terminal398 which is coupled to the processor 60. The circuit pattern assembly338 further includes a second state trace or conductor 394 of a zigzagpattern that terminates in a terminal 400 which is coupled to theprocessor 60. The processor 60 monitors the first and second traces 392,294 via the terminals 398, 400 to obtain signals thereon as provided bythe wiper 336.

The voltage trace 390 provides continuous voltage to the finger 380 asthe wiper assembly 332 is rotated. During rotation of the wiper assembly332, the middle finger 382 rotates in a circle that alternately makesand breaks contact with the first state trace 392 due to the zigzagpattern. At the same time, the outer finger 384 rotates in a circle thatalternately makes and breaks contact with the second state trace 394 dueto the zigzag pattern. It can be seen in FIG. 50 that the zigzagpatterns of the first and second traces 392, 394 provide areas whereonly the middle finger 382 provides a voltage (signal) from the innerfinger 380 to the processor 60, where only the outer finger 384 providesa voltage (signal) from the inner finger 380 to the processor, whereneither the middle or out finger 382, 384 provide a voltage (signal) tothe processor, and where both the middle and outer fingers 382, 384provide a voltage (signal) to the processor 60 during rotation of thewiper assembly 332.

A voltage may be considered a logic “1” while no voltage may beconsidered a logic “0”. Thus the wiper assembly 332 provides a “00”state (neither the middle finger 382 nor the outer finger 384 conducts avoltage), a “01” state (the middle finger 382 does not conduct a voltagewhile the outer finger 384 conducts a voltage), a “10” state (the middlefinger 382 conducts a voltage while the outer finger 384 does notconduct a voltage), and a “11” state (both the middle and outer fingers382, 384 conduct a voltage). The four states are not necessary in anyparticular order but do not repeat until all four states have been used.The processor 60 thus detects the state changes (by counting orotherwise). Also direction of rotation may be determined by knowing thestate changes and their sequence. The processor can thus produceposition signals for lighting the LEDs, keeping track of the position ofthe user cycle selector, and knowing the user selected operation cycle.Of course, it should be appreciated that variations of the above may beused, such as the number of fingers, trace patterns, and/or the like.

In the cycle operation mode, the washing machine 5 is operative to runthe particular selected cycle and rotation of the user cycle selectorhas no effect since the mode switch 328 is, during this time, in adeactivated state. The LEDs 307 of the particular selected cycle,however, alternatively light in sequence to show operating cycleprogression. The processor 60 provides cycle progression signals to thetransistor Q1, Q2, Q3, Q4, and Q5 (FIGS. 23 and 24) of the appropriatebank of LEDs 270, 272, 274, 276 and 278 (corresponding to theuser-selected cycle) to actuate that bank of LEDs 307, and to thedriver/buffer 238 as appropriate to light a particular LED 307 of theLED bank.

As an example, in FIG. 54, assume that the Cotton operating cycle hasbeen selected by the user during the user selection mode. This has beeninitially been indicated by lighting the start LED 401 (of the LEDs 307)as the user rotates the user knob 318. At the next stage of the cycle,defined by the program instructions in the memory 116 and executed bythe processor 60, the start LED 401 goes off and the next LED 402 goeson. At the next stage of the cycle, the LED 402 goes off and the nextLED 403 goes on. Finally, at the end of the cotton cycle, the last LED404 goes on and the previous LED 403 goes out. In this manner cycleprogression is indicated. The processor 60 provides cycle progressionsignals as appropriate.

FIG. 22 depicts the electrical diagram for the circuit pattern assembly.The terminal 396 receives a voltage for the conducting trace 390. Thefirst state output terminal 398 for the first state conducting trace 392is coupled to the processor 60 as an input thereto. Likewise, the secondstate output terminal 400 for the second state conducting trace 394 iscoupled to the processor 60 as an input thereto.

Operation Mode/Cycle Selector Shaft Detection and LED Indication ofOperation of Appliance and Control Knob Position

In accordance with another aspect of the present invention the appliancecontrol system 10 includes a main controller module 300 (FIG. 1)composed of various mechanical and electrical components that areconfigured to detect the position of the knob/dial assembly and producea position signal indicative of knob assembly position.

Referring to FIG. 55, there is depicted an exemplary shaftposition/rotation detection system generally designated 410 that may beutilized in either or both the user cycle selector 314 or any one or allof the auxiliary input units 44. In particular the shaftposition/rotation detection system (system) 410 is operative to detectrotational position and/or rotation speed of a shaft 418. The system 410includes a light transmitter or emitter 414 and associated lightdetector 416 each of which is under control via control/detectioncircuitry/logic 412. The control/detection circuitry/logic 412 is, inturn, under control via the processor 60 with the processor 60 undercontrol via program instructions stored in the memory 116.

The shaft 418 includes a disk 420 or other similar device that includesa plurality of apertures 422 spaced thereabout. The disk 420 is fixed inrelation to the shaft 418 such that the disk 420 rotates with the shaft418. The light transmitter 414 and the light detector 416 are positionedon either side of the disk 420 such that light from the lighttransmitter 414 can shine through the apertures 422 and be collected ordetected by the light receiver 416 as the disk 420 rotates (along withthe shaft 418). As the disk 420 rotates, the light from the lighttransmitter 414 alternately shines through an aperture to be detected orcollected by the light detector 416 and is blocked between adjacentapertures 422. This creates pulses of light that are received by thelight detector 416.

The pulses of light received by the light detector 416 are received bythe control/detection circuitry/logic 412 which are forwarded to theprocessor 60 for processing in accordance with program instructionsstored in the memory 116. The number of light pulses and the rate ofreception of the light pulses received or detected by the light receiverprovides shaft 418 position and velocity of rotation. It should beappreciated that the number of apertures 422 thus defines the resolutionof the rotational position of the shaft 418. Hence the more apertures,the more fine the determination of the angular or rotational position ofthe shaft 418.

Referring to FIG. 56, there is depicted another exemplary shaftposition/rotation detection system generally designated 430 that may beutilized in either or both the user cycle selector 314 or any one or allof the auxiliary input units 44. In particular the shaftposition/rotation detection system (system) 430 is operative to detectrotational position and/or rotation speed of a shaft 432. The system 430includes a system of either a hall effect sensor 436 and a plurality ofmagnets 428 or, in the alternative, a magnet 436 and a plurality of halleffect sensors. Since only the hall effect sensor(s) need to be coupledto detector circuitry/logic 442, it is preferable that there is only onehall effect sensor. In either case the principle and/or operation is thesame. The following will assume that the hall effect sensor is 436 andthe magnets are 438. Further, either the disk 434 on which the halleffect sensor 436 or the disk 440 having the plurality of magnets 438may rotate with the shaft 432 while the other of the respective disks440 and 434 is fixed with respect to the shaft 432.

As the magnets rotate relative the hall effect sensor, the hall effectsensor produces a signal. The signal is received by the detectioncircuitry/logic 442 which forward the signals to the processor 60. Theprocessor 60 under control of program instructions stored in the memory116 determines the angular or rotational position of the shaft 432and/or the rotational velocity of the shaft 432.

Referring to FIGS. 23 and 24, an electrical schematic of the LEDs 307and their control circuitry/logic are shown. While the LEDs 307 aremounted onto the circuit board so as to form a continuous circle, theLEDs 307 are divided into LED banks 270, 272, 274, 276, and 278. EachLED bank is then separately controlled as well as each particular LED ineach bank. The number of LED banks preferably corresponds to the numberof cycles or modes of operation of the washing machine 5. Each LED 307within an LED bank indicates and corresponds to a particular demarcationin the cycle. Depending on the particular cycle or mode, an LED mayindicate a different parameter, such as time remaining or mode withinthe cycle. Each LED bank 270, 272, 274, 276, and 278 is separatelyactuated as well as each LED within an actuated LED bank. Preferably,only one LED bank is actuated at a time (switched in). As well,preferably only one LED within an LED bank is caused to light at a time(actuated). Thus, a particular LED bank may be in an active mode (i.e.its LEDs can be caused to light) while the other LED banks are not in anactive mode (i.e. the LEDs cannot be lit) depending on the particularcycle selected by the user.

Each LED bank 270, 272, 274, 276, and 278 is in communication with arespective transistor Q1, Q2, Q3, Q4, and Q5 (electronic switches). Thebase of each transistor Q1, Q2, Q3, Q4, and Q5, is coupled to an outputof the processor 60. Particularly, the base (pin 2) of transistor Q1 iscoupled to output L3 of the processor 60. The base (pin 2) of transistorQ2 is coupled to output L1 of the processor 60. The base (pin 2) of thetransistor Q3 is coupled to output L4 of the processor 60. The base (pin2) of the transistor Q4 is coupled to output L2 of the processor 60. Thebase (pin 2) of the transistor Q5 is coupled to output L5 of theprocessor 60. It should be appreciated that this is arbitrary. Eachtransistor Q1, Q2, Q3, Q4, and Q5 thus actuates a particular LED bank,with each transistor Q1, Q2, Q3, Q4, and Q5 controlled by the processor60.

Each particular LED within an LED bank 270, 272, 274, 276, and 278 isconnected to one of only a number of actuation lines, the number ofactuation lines corresponding to the LED bank having the most number ofindividual LEDs. In FIGS. 23 and 24, the number of actuation lines issix (each LED bank 270, 272, 274, 276, and 278 has the same number ofLEDs). Each actuation line is coupled to an output of the driver/bufferIC 238. Thus each actuation line (IC output) actuates a particular LED.Particularly, the actuation lines are respectively connected to outputsY1, Y2, Y3, Y4, Y5, and Y6. This reduces the number of actuation linesand thus outputs of the driver/buffer IC 238. A particular LED cannotlight until its LED bank switch (transistor) is actuated and a signal isreceived on its actuation line. Each bank of LEDs as well as particularLEDs in the LED bank is separately controlled. The driver/buffer IC 238receives signals from the processor 60.

In summation, the driver/buffer IC 238 only has to provide an LEDactuation signal to a particular output (actuation line), while theprocessor 60 provides an LED bank actuation signal to a particular LEDbank, with the processor 60 providing the control signals to thedriver/buffer IC 238. In this manner, the processor 60 (under control ofthe program instructions) controls the lighting of the LEDs.

It should be appreciated that the number of LED banks are arbitrary, aswell as the number of LEDs in a particular LED bank. As well, eventhough each LED bank is shown having the same number of LEDs, this isnot necessary, as each bank of LEDs may have any number of LEDs. Forexample, one bank of LEDs may have only one LED while another bank ofLEDs may have fifteen LEDs. Various combinations are thus possible.

Network Accessible, Programmable Memory

In accordance with another aspect of the present invention, the washingmachine 5 (FIG. 1) is operative/adapted to be coupled to or incommunication with an external, public or private network such as theInternet via an integral interface. Referring to FIG. 20, the ACS 10also includes a communication port 50 (see FIG. 1) that is incommunication with the processor 60 via communication circuitry/logic234. The communication port 50 may be an RS-232 interface or the likethat is operative to allow the connection of the communication port 50to an external network 232. The external network 232 may be a publicnetwork such as the Internet, a private network such as a LAN, or thelike. The network 232 may also represent an external device that may betemporarily coupled to the communication port 50 so as to be incommunication with the ACS 10. The communication circuitry/logic 234 maybe an appropriate integrated circuit (IC), a modem, or the like. Thecommunication port 50 and the communication circuitry/logic 234 areoperative to allow connection to the network 232 and provided two-waycommunication between the processor 60 of the ACS 10 and the network232.

As indicated above, the ACS 10 includes memory 116 that stores programinstructions 236. The program instructions 236 provide operatinginstructions for the various operating characteristics/modes of thewashing machine as well as specific instructions for components thereof,diagnostics for the various components, and/or communication protocolsand the like. As well, the program instructions 236 encompass look-uptables, data, and the like, all of which are necessary as part of theoperation of the washing machine 5. In accordance with an aspect of thesubject invention, the program instructions 236 are modifiable and/oralterable by erasure and/or replacement thereof. Thus, the memory 116 isaccessible via the processor 60. The communication port 50 and thecommunication circuitry/logic 234 permit the introduction of new programinstructions into the memory 116 via the network 232 and the erasure ofold or unwanted program instructions.

Referring to FIG. 24, an electrical schematic form of the communicationport 505 and at least a portion of the communication circuitry/logic 234are shown. The communication port 5 is formed at connections P13,terminals 1, 2, and 3. The communication port 5 is in communication witha driver/buffer IC 238 as part of the communication circuitry/logic 234.Particularly, the communication port 5 is coupled to the RXIN ortransmit in (pin 9) of the IC 238 and a TXOUT or transmit out (pin 12)of the IC 238. This allows the communication port 5 to serially receiveand send data.

The IC 238 is in communication with the processor 60 (see FIG. 10) viaI/Os A1, A2, A3, A4, A5, and A6 on respective pins 7, 6, 5, 4, 3, and 2of the IC 238 and the respective pins 13, 14, 19, 20, 21, and 22 of theprocessor 60. The processor is in communication with the memory 116. Inthis manner, any external device may be in communication with the ACS 10via the network 232. Of course, the program instructions 236 may includea communications protocol as well as necessary firewall software,encryption software, and/or the like for secure communication over thenetwork 232. The communication port 50 also allows the remotetroubleshooting of problems with the washing machine 5 over the network232. Other functions include technical support of washing machineproblems.

Mechanics of the Appliance Control System

As mentioned above, the appliance control system 10 includes the maincontroller module 300. The main controller module 300 will be describedwith reference to FIGS. 25-52. Note that FIGS. 25-27 show the maincontroller module 300 substantially assembled, while FIGS. 28-52 shownvarious components, subassemblies, or exploded views of the maincontroller module.

The main controller module 300 includes a housing 302 that contains afirst printed circuit board 304 and a second printed circuit board 306(see e.g. FIGS. 26, 51, and 52). Each of the printed circuit boards 304,306 support various electronic, mechanical, and electromechanicalcomponents thereon whose operation will discussed in more detail inother parts of this disclosure.

Supported on the printed circuit board 304 is the auxiliary input port114 and the water temperature sensor port 241. Also supported on thefirst printed circuit board 304 is the plurality of light emittingdevices 307. (See e.g. FIGS. 28-29.) The light emitting devices 307 areLight Emitting Diodes (i.e. LEDs). The LEDs 307 form the display device20 for the main controller module 300 which operates to displayinformation about the operation of the washing machine 5. The LEDs 307are positioned relative to each other so as to form a ring as shown inFIGS. 28 and 51. FIGS. 29 and 30 show only some of the plurality of LEDs307 for clarity of viewing. The first printed circuit board 304 includesa front side 304F and a back side 304B, while the second printed circuitboard 306 includes a front side 306F and a back side 306B (see e.g.FIGS. 51-52). The LEDs 307 are mounted to the front side 304F of thefirst printed circuit board as shown in FIGS. 28-30 and 51.

The housing 302 includes a plurality of display apertures 358 defined ina front panel 360 thereof. The display apertures 358 are positionedrelative to each other so as to form a ring (see e.g. FIG. 25). Thehousing 302 further includes a rib structure 362 that extends from thefront panel 360 towards the interior of the housing 302 (see e.g. FIGS.33 and 35). The rib structure 362 defines a plurality of receptacles 364which are positioned relative to each other so as to form a ring. Whenthe main controller module 300 is assembled, the LEDs 307 respectivelyextend into the plurality of receptacles 364. Accordingly, lightgenerated by the LEDs 307 during operation of the appliance controlsystem 10 is transmitted from within the interior of the housing 302 toa location outside of the housing 302 through the display apertures 358for viewing by a user of the washing machine 5.

The main controller module 300 further includes an escutcheon 308 thatis secured to the housing 302 as shown in FIGS. 25-26. In particular,the escutcheon 308 includes a pair of tabs 309 (see FIGS. 36-38) thatare respectively received in a pair of apertures 311 defined in thehousing 302 (see FIGS. 33-35) so as to secure the escutcheon 308 to thehousing 302. The escutcheon 308 has a passageway 310 that extendstherethrough (see FIG. 38). The escutcheon 308 is made of a materialthat allows light to pass through it. For example, the escutcheon 308can be made of a translucent material that diffuses light as it passesthrough the escutcheon. Thus, a user viewing a completely assembled maincontroller module 300 may view light being generated by the LEDs 307through the display apertures 358 and escutcheon 308.

The main controller module 300 further includes a user cycle selectorassembly 312 that extends through the passageway 310 of the escutcheon308 when the main controller module 300 is assembled as shown in FIGS.25-26. The selector assembly 312 includes a user cycle selector 314. Theuser cycle selector 314 includes a control shaft 316 and a user knob318. The knob 318 is secured to an end of the control shaft 316 so thatrotation of the knob 318 causes rotation of the control shaft 316.

As shown in FIGS. 41 and 42, the control shaft 316 has a central axis340. The control shaft also has a pair of legs 342 which are configuredto connect to the knob 318. The control shaft 316 further has anincreased diameter portion 344, an intermediate portion 346, and areduced diameter portion 348. The intermediate portion 346 has a firstgroove 350 and a second groove 352 defined therein. The intermediateportion 346 further has defined therein a contact member 354 in the formof a ring-shaped flange. The reduced diameter portion 348 possesses asubstantially D-shaped cross-section as shown in FIG. 44. Moreover, thereduced diameter portion 348 has a keyed surface 356 which extends alongits length as shown in FIG. 41.

The selector assembly 312 further includes a first spring 320 that issecured to the housing 302 (see e.g. FIGS. 33 and 45-46). The firstspring has a pair of spring arms 321. In order to secure the firstspring 320 to the housing 302, the housing includes a moveable clip 322,a retaining structure 324 that defines a slot 326, and a pair of spacedapart retaining arms 328 (see e.g. FIGS. 33-35). In particular, thefirst spring 320 is retained in fixed relation to the housing 302 as aresult of being advanced between the pair of retaining arms 328, andthrough the slot 326 of the retaining structure 324, and then adjacentto the clip 322 as shown in FIG. 33. The clip 322 includes a lip 330configured to retain the first spring 320 in position after the spring320 is advanced to its position shown in FIG. 33.

The selector assembly 312 further includes a wiper assembly 332 as shownin FIGS. 28, 30 and 47-49. (Note that FIG. 28 only schematically showsthe wiper assembly 332.) The wiper assembly 312 includes a carriermember 334 and an electrically conductive wiper 336 that is securedthereto. The wiper 336 may be secured to the carrier member 334 by ariveting process. After assembly of the main controller module 300, thewiper assembly is positioned into contact with a circuit patternassembly 338 that is supported on the backside 304B of the first printedcircuit board 304 (see e.g. FIG. 52).

The carrier member 334 includes a shaft hole 366 defined therein. Theshaft hole defines a keyed surface 368. After assembly of the maincontroller module 300, the reduced diameter portion 348 of the controlshaft 316 extends through the shaft hole 366 so that the keyed surface356 aligns with the keyed surface 368. Accordingly, rotation of thecontrol shaft 316 causes a corresponding rotation of the wiper assembly332.

The carrier member 334 further includes a hub 370. The hub 370 has a hubgroove 372 defined therein preferably for an O-ring or the like (notshown). Note also that the first printed circuit board 304 has a shaftpassage 374 defined therein (see e.g. FIG. 51). The shaft passage 374defines an interior peripheral edge portion 376. After assembly of themain controller module 300, the interior peripheral edge portion 376 islocated circumferentially adjacent the O-ring and/or the hub groove 372.Note that the outer diameter of the hub groove 376 and the innerdiameter of the shaft passage 374 are configured so that the hub 370 isattached to the first printed circuit board 304, yet the hub 370 mayfreely rotate relative to the first printed circuit board 304.Accordingly, the carrier member 334 is rotatably secured to the firstprinted circuit board 304. When the carrier member is rotatably securedto the first printed circuit board 304 in the above-described manner,the wiper 336 contacts the circuit pattern assembly 338 during rotationof the wiper assembly 332.

The selector assembly 312 further includes a second spring 377 and amode switch 378 (see e.g. FIGS. 29-30 and 39-40). Both the second spring377 and the mode switch 378 (see SW1 of FIG. 22) are secured to thefirst printed circuit board 304 as shown in FIG. 29. The second spring377 includes a spring arm 380 that is movable in the direction 382toward the mode switch as shown in FIG. 29. The mode switch 378 includesa plunger 384 that is movable between a raised position and a depressedposition. The plunger 384 is spring biased into its raised position.When force is applied to the second spring 377 in the direction of arrow382 as shown in FIG. 29, the spring arm 380 moves downwardly andcontacts the plunger 384 so as to depress the plunger 384 and move itfrom its raised position to its depressed position. When the plunger 384is in its raised position, the mode switch 378 is in a deactuated state.However, when the plunger 384 is in its depressed positioned, the modeswitch 378 is in an actuated state.

The mechanical operation of the main controller module 300 is asfollows. A user grasps the knob 318 and pushes it inward in thedirection of arrow 386. As a result, the control shaft 316 is alsopushed inward in the direction of arrow 386 from a first axial positionto a second axial position. In response to the inward movement ofcontrol shaft 316, the spring 320 is forced to move out of the groove352 and into the groove 350 (see e.g. FIG. 29). In particular, withmovement of the control shaft 316, the surface of the control shaft thatdefines the groove 352 moves in a corresponding manner. With suchmovement of the surface that defines the groove 352, such surfacecontacts and urges the spring arms 321 outwardly relative to each otherthereby allowing the control shaft 316 to move in an axial directionfrom its first axial position to its second axial position. When thecontrol shaft is in its second axial position, the first spring 320 islocated in the groove 350 thereby retaining the control shaft in thesecond axial position.

As the control shaft is moving in the direction of arrow 386, thecontact member 354 forces the spring arm 380 downwardly in the directionof arrow 382. As the spring arm 380 is forced downwardly, the spring arm380 contacts the plunger 384 of the mode switch 378 and moves theplunger downwardly from its raised position to its depressed positionthereby causing the mode switch 378 to be switch out of its deactuatedstate and into its actuated state.

It should be noted that when the mode switch 378 is in its deactuatedstate, the appliance control system 10 is caused to operate in its cycleoperation mode. Further, when the mode switch 378 is placed in itsactuated state, the appliance control system 10 is caused to operate inits user cycle selection mode. The details of operation of the appliancecontrol system 10 in its cycle operation mode and its user cycleselection mode are discussed in more detail in other parts of thisdisclosure.

It should be appreciated that the contact member 354 will be able tocontact the spring arm 380 irrespective of the rotational position ofthe user cycle selector 314. This feature results from the shape of thecontact member 354. In particular, the contact member 354 is configuredto be a ring-shaped flange thereby extending outwardly around the entire360° periphery of the control shaft 316.

As an alternative embodiment, a plurality of detent grooves 388 may bedefined in the contact member 354 as shown in FIG. 29. The detentgrooves 388 would extend around the entire 360° periphery of a topsurface and/or of an edge of the contact member 354. For clarity ofviewing, FIG. 29 only shows the detent grooves 388 defined in part ofthe top surface of the contact member 354. The housing 302 may include anumber of detent arms 390 which extend inwardly from the front panel 360of the housing 302 as shown in FIG. 35. When the main controller module300 is assembled, the detent arms 390 would cooperate with the detentgrooves 388 to provide tactile feedback to a user when the user rotatesthe user cycle selector 314 about its central axis 340. Of course, as analternative, the detent arms may be provided on the contact member 354and the detent grooves may be defined in the housing 302. In such analternative arrangement, tactile feedback would also be provided to auser when the user rotates the user cycle selector 314 about its centralaxis 340.

Other Features

Referring to FIG. 21, the ACS 10 includes other various features and/orfunctions. One such feature is a water temperature sensor 240. The watertemperature sensor 240 is operative to provide water temperaturemeasurement data of the water for the water receptacle 32. The watertemperature data is used by the processor 60 to control the input ofwater to the receptacle 32 for the various washing modes of the washingmachine 5. The water temperature sensor 240 is thus associated with thereceptacle 32. The water temperature measurement data from the watertemperature sensor 240 is provided to the processor 60.

The ACS 10 utilizes program instructions stored in the memory 116 tocontrol the application of hot and cold water into the receptacle 32. Inthis regard, the ACS 10 further includes a water supply control 242 thatincludes a water level sensor 244, a hot water control 246, and a coldwater control 248. The water level sensor 244 is operative to measure,detect, and/or monitor the water level in the receptacle 32. The hotwater control 246 is operative to control the application of hot waterinto the receptacle 32. The cold water control 248 is operative tocontrol the application of cold water into the receptacle 32. Controlledmixtures of hot and cold water result in various temperature of waterfor the washing of laundry, typically as set by the user via theauxiliary input units, in the receptacle 32.

In FIG. 22, there is shown a schematic diagram of at least a portion ofan implementation of the water supply control 242. Water level sensorcircuitry/logic 244 includes a terminal P3, pin 1, to which a waterlevel sensor is coupled. Water level data or signals are received viathe terminal P3, pin 1, and, after signal conditioning, is forwarded tothe processor 60. The hot water control circuitry/logic 246 includes atriac Q13 that is actuated by the processor 60. Once actuated, the triacQ13 applies power to a solenoid (not shown) that is coupled to P3, pin3. The solenoid opens and closes a hot water valve. In the same manner,the cold water control circuitry/logic 248 includes a triac Q12 that isactuated by the processor 60. Once actuated, the triac Q12 applies powerto a solenoid (not shown) that is coupled to P3, pin 4. The solenoidopens and closed a cold water valve. It should be appreciated that thehot and cold water circuitry/logic 246, 248 are interchangeable.

Referring to FIG. 11, the water temperature sensor 240 is input atterminal P1, pins 1 and 3. The processor 60 receives water temperaturedata/signals. The processor 60 uses the water temperature data/signalsto control the hot and cold water controls 246 and 248.

Referring to FIG. 12, terminals P11 pins 1, 2, 3, 4, and 5 form an input250 to the processor 60. The input 250 is used for flash programming theprocessor 60. As well, the input 250 may be used for emulating variousfunctions of the ACS 10 for testing and/or diagnostic purposes. Theinput 250 is typically not necessary and may be eliminated if desired.

Application to Other Laundry Appliances

Referring to FIG. 57, there is depicted a dryer, generally designated 6,representing another form of a laundry appliance. The dryer 6 includescomponents that are the same as the washing machine 5 and are designatedby the same reference numeral primed. The dryer 6 has a frame 36′ thathouses a receptacle or tub 32′ that is configured to receive laundrytherein. The tub 38′ receives laundry for drying via a pivoting door 38′in the frame 36′. The tub 36′ is mounted in the frame 32′ so as torevolve or spin, typically around a horizontal axis. The tub 38′ is incommunication with a motor 26′ that is likewise mounted in the frame36′, and which is operative to spin the tub 38′ in a controlled manner.The motor 26′ however, is a one-speed motor adapted/operative to rotatethe tub 38′ at one speed.

The dryer 6 also has a control panel frame 40′ that houses an appliancecontrol system 10′. External to the control panel frame 40′ and part ofthe appliance control system 10′ is a controller module 300 and aplurality of auxiliary inputs 44′ (typically in the form of knob,switches, or the like). The controller module 300 provides operatingmode/cycle indication and/or control of the operating mode/cycle for/ofthe dryer 6. Power for the dryer 6 is provided via a power cord 48′ thatis configured to be plugged into an appropriate source of electricity,typically a 120 volt AC source or a 240 volt AC source (not shown). Thegeneral operation of the dryer 6, with respect to the loading, drying,and unloading of laundry, is typical of dryers.

The appliance control system 10′ also includes a communication port 50′that allows the dryer 6 to be coupled to an external device, network, orthe like. The communication port 50′ may take the form of an RS-232port, a telephone-type port, or the like. Particularly, thecommunication port 50′ allows the dryer 6 to be in communication with atest/diagnostic device, a public and/or private network such as theInternet, another laundry appliance, or other device.

It should thus be appreciated that the washing machine 5 and the dryer 6are examples of laundry appliances which may incorporate the variousaspects and principles of the invention therein. As such, the washingmachine 5 and the dryer 6 share common characteristics such as themanner in which the laundry appliance is controlled including theappliance control system 10′, the use and type (but typically not thefunction) of the auxiliary user interface system including the auxiliaryinputs 44′, and the selector display 20′. The term laundry appliance orappliance thus applies to washers, dryers, and the like, unlessspecifically mentioned otherwise. In the case or to the extent that afeature, function or manner of operation applies only to a washingmachine but not a dryer, and vice versa, such has been indicated.

Application to Other Appliances/Devices

It should be further appreciated that the ACS 10 and/or other featuresshown and described herein may be used in appliances other than laundryappliances which require control and/or operation indication such asovens, stoves, and the like (collectively kitchen appliances), as wellas other appliances. Likewise, they may be used in other devices asappropriate.

It should be appreciated that the various aspects of the presentinvention have been described separately herein. These various aspects,however, may be utilized in any combination by any type of laundryappliance. Further, the various aspects may be utilized in devices otherthan laundry appliances.

While this invention has been described as having a preferred designand/or configuration, the present invention can be further modifiedwithin the spirit and scope of this disclosure. This application istherefore intended to cover any variations, uses, or adaptations of theinvention using its general principles. Further, this application isintended to cover such departures from the present disclosure as comewithin known or customary practice in the art to which this inventionpertains and which fall within the limits of the claims.

What is claimed is:
 1. An appliance control system which is operable ina user cycle selection mode and a cycle operation mode, comprising: ahousing; a display device supported by said housing; a user cycleselector at least partially positioned within said housing; a printedcircuit board supported by said housing; a circuit configured to (i)operate said display device during said user cycle selection mode toindicate position status of said user cycle selector; and (ii) operatesaid display device during said cycle operation mode to indicate cycleprogression status of said appliance control system, said circuitincludes a circuit pattern assembly supported by said printed circuitboard; and a wiper assembly positioned within said housing; wherein saiduser cycle selector is movable from a first selector position to asecond selector position in relation to a circuit pattern assembly,wherein said circuit is configured to operate said display device toindicate a first position status which corresponds to said firstselector position when said wiper assembly is positioned in contact withsaid circuit pattern assembly at a first orientation, and wherein saidcircuit is configured to operate said display device to indicate asecond position status which corresponds to said second selectorposition when said wiper assembly is positioned in contact with saidcircuit pattern assembly at a second orientation.
 2. The appliancecontrol system of claim 1, wherein: said user cycle selector includes acontrol shaft, said wiper assembly includes a carrier member and awiper, said wiper is supported on said carrier member, said carriermember has a shaft hole defined therein, and said control shaft extendsthrough said shaft hole.
 3. The appliance control system of claim 2,wherein said carrier member is rotatably secured to said printed circuitboard.
 4. The appliance control system of claim 3, wherein: said printedcircuit board has a shaft passage extending therethrough, said shaftpassage defines an interior peripheral edge portion, said carrier memberincludes a hub having a hub groove defined therein, and said interiorperipheral edge portion is located in said hub groove.
 5. The appliancecontrol system of claim 2, wherein said user cycle selector furtherincludes a user knob secured to an end of said control shaft.
 6. Theappliance control system of claim 2, wherein: said control shaft definesa first keyed surface, said shaft passage defines a second keyedsurface, and said first keyed surface aligns with said second keyedsurface when said control shaft extends through said shaft passage. 7.The appliance control system of claim 1, wherein said display deviceincludes a plurality of light emitting diodes.
 8. An appliance controlsystem which is operable in a user cycle selection mode and a cycleoperation mode, comprising: a display device; a user cycle selectorwhich is movable from a first selector position to a second selectorposition; a wiper assembly; and a circuit configured to (i) operate saiddisplay device during said user cycle selection mode to indicateposition status of said user cycle selector; and (ii) operate saiddisplay device during said cycle operation mode to indicate cycleprogression status of said appliance control system, said circuitincludes a circuit pattern assembly; wherein said circuit is configuredto operate said display device to indicate a first position status whichcorresponds to said first selector position when said wiper assembly ispositioned in contact with said circuit pattern assembly at a firstorientation, and wherein said circuit is configured to operate saiddisplay device to indicate a second position status which corresponds tosaid second selector position when said wiper assembly is positioned incontact with said circuit pattern assembly at a second orientation. 9.The appliance control system of claim 8, wherein: said user cycleselector includes a control shaft, said wiper assembly includes acarrier member and a wiper, said wiper is supported on said carriermember, said carrier member has a shaft hole defined therein, and saidcontrol shaft extends through said shaft hole.
 10. The appliance controlsystem of claim 9, further comprising a printed circuit board, whereinsaid carrier member is rotatably supported on said printed circuitboard.
 11. The appliance control system of claim 10, wherein: saidprinted circuit board has a shaft passage extending therethrough, saidshaft passage defines an interior peripheral edge portion, said carriermember includes a hub having a hub groove defined therein, and saidinterior peripheral edge portion is located in said hub groove.
 12. Theappliance control system of claim 9, wherein said user cycle selectorfurther includes a user knob secured to an end of said control shaft.13. The appliance control system of claim 9, wherein: said control shaftdefines a first keyed surface, said shaft passage defines a second keyedsurface, and said first keyed surface aligns with said second keyedsurface when said control shaft extends through said shaft passage. 14.The appliance control system of claim 8, wherein said display deviceincludes a plurality of light emitting diodes.
 15. An appliance controlsystem which is operable in a user cycle selection mode and a cycleoperation mode, comprising: a user cycle selector; a wiper assembly,wherein movement of said user cycle selector causes movement of saidwiper assembly; and a circuit pattern assembly positioned in contactwith said wiper assembly; wherein switching of said appliance controlsystem from said user cycle selection mode to said cycle operation modewhen said wiper assembly is positioned in contact with said circuitpattern assembly at a first orientation causes a first selected cycle ofsaid cycle operation mode to be performed by said appliance controlsystem, and wherein switching of said appliance control system from saiduser cycle selection mode to said cycle operation mode when said wiperassembly is positioned in contact with said circuit pattern assembly ata second orientation causes a second selected cycle of said cycleoperation mode to be performed by said appliance control system.
 16. Theappliance control system of claim 15, wherein: said first selected cycleincludes a delicate cycle, said second selected cycle includes apermanent press cycle.
 17. The appliance control system of claim 15,wherein: said first selected cycle includes a cotton cycle, and saidsecond selected cycle includes a delicate cycle.
 18. The appliancecontrol system of claim 15, wherein: said user cycle selector includes acontrol shaft, and said wiper assembly includes a carrier member and awiper, said wiper is supported on said carrier member, said carriermember has a shaft hole defined therein, and said control shaft extendsthrough said shaft hole.
 19. The appliance control system of claim 18,further comprising a printed circuit board, wherein said carrier memberis rotatably supported on said printed circuit board.
 20. The appliancecontrol system of claim 19, wherein: said printed circuit board has ashaft passage extending therethrough, said shaft passage defines aninterior peripheral edge portion, said carrier member includes a hubhaving a hub groove defined therein, and said interior peripheral edgeportion is located in said hub groove.
 21. The appliance control systemof claim 18, wherein said user cycle selector further includes a userknob secured to an end of said control shaft.
 22. The appliance controlsystem of claim 18, wherein: said control shaft defines a first keyedsurface, said shaft passage defines a second keyed surface, and saidfirst keyed surface aligns with said second keyed surface when saidcontrol shaft extends through said shaft passage.